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740 Turbo Diesel '89 2.4L - serious smoke-out at start-up after standing overnight 700 1989

posted by  GeorgeB on  Mon Jul 30 02:59 CST 2007
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last visit: Mon Jul 30 03:03 CST 2007
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is 6-cyl VW engine version ... on start-up enormous volume of smoke from exhaust .. seems that fuel is leaking into manifolds possibly via fuel pump and/or fuel cut-off solenoid ... any ideas/experiences ? would complete pump need replacing, presumably no pump recon kit, or can solenoid valve be replaced on its own ? Rgds GeorgeB








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    740 Turbo Diesel '89 2.4L - serious smoke-out at start-up after standing overnight 700 1989

    posted by  dnastrau on  Tue Jul 31 06:02 CST 2007
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    last visit: Mon Dec 5 19:39 CST 2011
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    Hi George:

    I had a VW Jetta 1.6 Diesel - basically the same injection setup as far as I know. Here are some thoughts:

    It sounds like you could have leaking fuel injectors that are allowing fuel to leak into the prechambers after shut-down. Try getting them pressure tested, set to spec and cleaned. You may need to get them rebuilt or swap in for units already rebuilt.

    The fuel pump may be out of time. The proper way to set the pump timing involves some special tools including a dial indicator that screws into the back of the fuel pump and locking tools that set the pump cog wheel and camshaft where they need to be in order to time the pump. Some say that they can set the timing by "ear" but I never tried that. You might want to look at the forum at this site if no one here can offer any additional help:

    http://www.vwdieselparts.com/forum/

    I would look in the general (non-TDI) forum in your case.

    I occasionally saw Volvo 2.4TD folks posting there even though the forum is focused on VWs.

    How are the glow plugs? Even one bad glow plug can cause rough running at startup and smoking especially if it is cool outside.

    How is your oil consumption? Your valve stem seals and/or valve guides could be worn.

    Your turbocharger's shaft seal could be bad as well causing oil to get sucked into the intake side.

    These are a few ideas that I had harking back to my Diesel days. Good luck with it!

    Andrew S.

    '91 744 B230F







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